Induction Heating Fusing Device with Nested Nip Rollers
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Solution Overview
Problem
Conventional fusing devices in electrophotographic image forming apparatuses face challenges in achieving a large nip size and durability while maintaining a compact design, and they often require high pressure between rollers, which can lead to reduced fusing quality and increased energy consumption.
Innovation Solution
The proposed solution involves an induction heating type fusing device with a closed-loop fusing belt, magnetic flux generator, and a compressing roller system that includes a nip guide, allowing for efficient induction heating and forming multiple nips to ensure high fusing quality and durability, while maintaining a compact size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional fusing device uses a halogen lamp for heating, then the printing medium can be heated, but the temperature rise is slow and power consumption is high
Solution Approach 1:
The patent replaces the conventional halogen lamp heating system with an induction heating system. The induction heating device uses a magnetic flux generator to generate electromagnetic fields that directly induce eddy currents in the heating layer, converting electromagnetic energy directly into heat without mechanical or thermal radiation intermediaries. This substitution achieves faster temperature rise and lower power consumption.
Solution Approach 2:
The patent changes the heating mechanism parameter from thermal radiation (halogen lamp) to electromagnetic induction (magnetic flux generator). By changing the heating principle and using induction heating with a conductive heating layer, the system achieves more efficient energy conversion, faster heating response, and reduced power consumption while maintaining the required fusing temperature.
2Manufacturing precision
If high pressure is applied between rollers to achieve large nip, then fusing quality improves, but device complexity and energy consumption increase
Solution Approach 1:
The patent divides the single large nip into multiple smaller nips by introducing idler rollers between the compressing roller and the fusing belt. This segmentation allows the system to achieve the same total fusing effect through multiple contact points, reducing the complexity of applying and controlling high pressure while maintaining or improving fusing quality.
Solution Approach 2:
The patent transforms the pressure distribution from a single-point high-pressure contact to a distributed multi-point contact system. By adding idler rollers, the pressing force is distributed across multiple nips along the fusing belt, changing the dimensional distribution of pressure application and reducing the complexity of the compressing mechanism.
3Volume of moving object
If a compact fusing device design is implemented, then device size is reduced, but achieving large nip size becomes difficult
Solution Approach 1:
The patent arranges multiple idler rollers and nips in a nested configuration within the compact fusing device. The idler rollers are positioned to create multiple contact points between the fusing belt and compressing roller, effectively nesting multiple pressing functions within a limited space. This allows the device to maintain a compact overall size while providing sufficient total nip length through multiple sequential contact points.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration ensures a large nip size for improved fusing quality, reduces the need for high pressure, and results in faster temperature rise and lower power consumption, enabling high-speed fusing with enhanced durability and compact device design.
Implementation Method 1
a magnetic flux generator disposed outside the fusing belt to emit magnetic flux for induction heating of the fusing belt
Implementation Method 2
magnetic flux generator disposed outside the fusing belt to emit magnetic flux for induction heating of the fusing belt
Data Source
AI summary
An induction heating type fusing device and an image forming apparatus including the fusing device. The fusing device includes a magnetic flux generator and a compressing roller outside a fusing belt, first and second fusing rollers and a nip guide inside the fusing belt. The compressing roller compresses against the first and second fusing rollers and the nip guide to form nips, while the fusing belt is disposed between the compressing roller and the first and second fusing rollers and the nip guide.